Recently, issues concerning the sustainable and harmless disposal of organic solid waste have generated interest in microbial biotechnologies aimed at converting waste materials into bioenergy and biomaterials, thus contributing to a reduction in economic dependence on fossil fuels. To valorize biomass, waste materials derived from agriculture, food processing factories, and municipal organic waste can be used to produce biopolymers, such as biohydrogen and biogas, through different microbial processes. In fact, different bacterial strains can synthesize biopolymers to convert waste materials into valuable intracellular (e.g., polyhydroxyalkanoates) and extracellular (e.g., exopolysaccharides) bioproducts, which are useful for biochemical production. In particular, large numbers of bacteria, including Alcaligenes eutrophus, Alcaligenes latus, Azotobacter vinelandii, Azotobacter chroococcum, Azotobacter beijerincki, methylotrophs, Pseudomonas spp., Bacillus spp., Rhizobium spp., Nocardia spp., and recombinant Escherichia coli, have been successfully used to produce polyhydroxyalkanoates on an industrial scale from different types of organic by-products. Therefore, the development of high-performance microbial strains and the use of by-products and waste as substrates could reasonably make the production costs of biodegradable polymers comparable to those required by petrochemical-derived plastics and promote their use. Many studies have reported use of the same organic substrates as alternative energy sources to produce biogas and biohydrogen through anaerobic digestion as well as dark and photofermentation processes under anaerobic conditions. Therefore, concurrently obtaining bioenergy and biopolymers at a reasonable cost through an integrated system is becoming feasible using by-products and waste as organic carbon sources. An overview of the suitable substrates and microbial strains used in low-cost polyhydroxyalkanoates for biohydrogen and biogas production is given. The possibility of creating a unique integrated system is discussed because it represents a new approach for simultaneously producing energy and biopolymers for the plastic industry using by-products and waste as organic carbon sources.

Although poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) is the most promising biopolymer for petroleum-based plastics replacement, the low processes productivity as well as the high sale price represent a major barrier for its widespread usage. The present work examines comparatively the existing methods to enhance the yield of the PHBV co-polymer biologically produced and/or reduce their costs. The study is addressed to researchers working on the development of new biological production methods and/or the improvement of those currently used. At this aim, the authors have considered the analysis of some crucial aspects related to substrates and microorganism’s choice. The production strategies have been individuated, presented and discussed, either based on a single aspect (type of substrate or microorganism) or based on combined aspects (type of substrate and microorganism). Process operating conditions have been discussed as well. The analysis indicates that the addition of 3HV precursors is capable to dramatically enhance the hydroxyvalerate fraction in the produced biopolymers. On the other hand, due to the high costs of the 3HV precursors, the utilization of wild bacterial species capable to produce the hydroxyvalerate fraction from unrelated carbon sources (i.e. no 3HV precursors) also can be considered a valuable strategy for costs reduction. Moreover, metabolic engineering techniques can be successfully used to promote 3HV precursors-independent biosynthesis pathways and enhance the process productivity. The use of mixed cultures or extremophile bacteria avoids the need of sterile working conditions, and therefore favours the process scale-up. The utilization of the organic waste as substrate plays a key role for a sharp reduction of production costs. Finally, the selection of the most suitable substrate-microorganism combination cannot be separated by the adoption of an appropriate choice of reactor configuration and abiotic factors. Graphic abstract